Electrical control device



Feb. 20, 1962 J. L. BONANNO 3,022,445

- ELECTRICAL CONTROL DEVICE Filed July 8, 1959 INVENTOR JZJJEPH Z. fla/m/vlvp ATTORNEYS United States Patent 3,022,445 ELECTRKCAL CONTROL DEVICE Joseph L. llonanno, outh Orange, NJZ, assignor to The Lionel Corporation, New York, N.Y., a corporation of New York Filed .luly 8, 1959, Ser. No. $25,721 12 Claims. (Cl. 317-40) This invention relates in general to electrical control devices and in particular to a new and useful variable resistor and reversing switch control device.

The present invention is particularly adaptable for use in association with the control of the operation of railroad trains in a model railway but may be employed in other applications where it is desired to vary both the current and the direction of flow in a direct current powered device.

In accordance with the present invention there is provided a compact combination reversing and switching device having complementary semi-annular segmental ring cores made or" highly conductive material, such as copper, over which is wound a variable resistance wire element. The device includes insulation between semiannular segments of the conductive ring to isolate variable control portions for each direction of current flow. The device includes a contact arm which is arranged to sweep over the resistance element wire windings in order to vary the resistance which is cut into a circuit by the device and the direction of current how in the circuit.

A feature of the invention is the compact arrangement of the control which permits simple control of current in both directions by rotating a simple handle control.

A further feature of the invention is the provision of the highly conductive copper ring cores over which the resistance wire is wound andwhich includes portions which are free of such wire to define heat-dissipating areas for rapid conduction and dissipation of heat from the resistance wire portions. Each segment includes a lar e exposed area of the conductive material which rapidly dissipates heat to the atmosphere and insures that the heat will not be concentrated within the resistance elements so that it does not build up to any excessive extent.

A feature of the present invention is the ease in which the device may be used in association with one or more similar devices for the control of one or more track sections in a model railway. The device includes 2. laterally extending contacting portion having screw terminals which may be connected to a power input source and includes a laterally extending receptacle portion constructed to receive a laterally extending contacting portion of a similar device after the terminal screws have been removed therefrom. The arrangement permits quick tandem connection of these devices and separate track section control, by connecting their output terminals to separate track sections which have been insulated from one another.

A further feature of the invention is the compact arrangement of the parts of the device including a panel board having a centrally positioned control handle which may be moved either in one direction or the other to control the amount of resistance and hence the speed of a train in either a forward or a reverse direction. The device includes a switch incorporated in the panel for temporarily disconnecting the current supply for the purposes of temporarily stopping and uncoupling a train. A suitable power light indicator is provided in the panel to indicate when current is being delivered to the track section.

Accordingly, it is an object of this invention to provide an improved, variable resistor and current control switch, including separated conductive ring segments over a portion of which'resistance wire elements are wound and a central arm which sweeps over each of the resistance wire elements in order to vary the resistance in a circuit and change the direction of current, and including por ions of the conductive ring segments which extend outwardly from the resistance wire windings to permit rapid dissipation of heat.

A further object of the invention is to provide a model railway panel control device, including means for varying the input current into a track section in both directions and incorporating a switch for interrupting the how of current to such sections.

A further object of the invention is to provide a variable resistor and current direction control device which is simple in design, rugged in construction and economical to manufacture.

The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this specification. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.

In the drawings:

FIG. 1 is a perspective view of a combination variable resistor and reversing switch panel control constructed in accordance with the invention;

FIG. 2 is a top plan view of the switch indicated in FIG. 1 with the panel cover removed;

FIG. 3 is an electrical wiring diagram for the switch indicated in FIG. 1; and

FIG. 4 is a somewhat schematic plan of an arrangement of two switches in tandem for controlling separate sections of track.

Referring to the drawings in particular, the invention as embodied therein includes a mounting plate generally designated 10 which is covered by a substantially blockshapecl console panel member or cover member generally designated 12.

In accordance with the invention the mounting plate it is provided with a set of opposite curved upstanding shoulder abutments l4 and 16 which are located in opposed relationship to receive half annular ring segments 18 and 20 which are anchored in the shoulder abutments in complementary opposed positions. The mounting plate 10 is provided with a central raised cylindrical boss 22 having a central bore which receives a stubbed shaft member 24. Abutment means (not shown) are provided on the shaft and boss to limit the rotation of the shaft to one half of a revolution.

Each of the conductive ring segments 18 and 20 is provided with a resistance wire winding 26 and 28 respectively which is insulated from its associated segment by suitable insulation material. Each winding 26 and 28 is connected at one end to its associated conductive ring segment.

The mounting plate 10 is provided with two aligned laterally extending portions 30 and 32, which accommodate two elongated metal contact members 34 and 36, the latter extending completely across the mounting plate. One of the contact members 34 is secured to the ring 29 through an upstanding lug portion 38 which extends through an opening in the ring 20 and is bent therearound to be secured thereto in tight electrical conducting relationship. The other member 36 is connected to the ring 18 by a lug portion 40 which is secured to the ring 18 in a similar manner. The portion 30 extends outwardly from the plate member 10 a greater distance than the portion 32 and the contact members 34 and 36 are provided with contact element securing screws 42 and 44 which are provided to fasten input terminals to each of the contact members 34 and 36 at this location. The opposits ends of the contact terminals 34 and 36 are biased downwardly toward the plate and the plate is recessed as at 45 to define a socket opening to permit insertion of a laterally extending portion similar to the portion 3th of another unit for connecting of the devices in tandem if desired.

Affixed to the shaft 24 for rotation therewith is a lower contact sweep arm 48 and an upper contact sweep arm 5%} which are insulated from one another and which may be rotated with the shaft 24 under the control of a control handle 52 to cause the arm 50 to sweep over either one of the resistance wires 26 or 23 and to cause the arm 43 to sweep over conductor ring segments 18 or depending on the direction of rotation of the handle 52. When the handle 52 is moved to the left from the neutral position indicated in FIG. 1, the arm 50 rides on the resistance wire element 28 and the arm 48 rides on the conductor ring segment 18 input current then flows from the terminal 36 through the conductor ring segment 18 and then through arm 43 to a conductive member 52 which is fastened to the plate It) and extends outwardly on an outwardly extending rear section 54 thereof. The contact member 54 is provided with a terminal screw 56 to permit connection of this portion to a circuit requiring current control such as a track section.

Current which flows into the terminal member 34 travels through the conductive ring segment 20 and then through the resistance 28 and through the arm 50 and a contact member 56 which connects the arm 50 at its central portion.

The contact member 58 is provided with an upstanding resilient portion 60 including an angled portion which is presented beneath a control button 62 in an upper console panel 64 of the cover member 12. The button 60 may be depressed to interrupt the circuit for such purposes as uncoupling a train section when such trains are positioned on a track structure in alignment with a conpler actuator (not shown). Normally the arm 60 is biased into contact with a contact member 66 which terminates in a contact button 68. The contact button 68 and the contact member 66 are secured to but insulated from a contact terminal member 70. The terminal member 76 is provided with a single securing stud 72 for connecting this terminal of the device to a circuit requiring current control. The contact member '70 is also provided with a resilient bimetallic member '74 which is welded to an outstanding portion 76 of the contact member 72 and is provided with a button portion 73 which is normally biased into contact with the button 68 of the member 66. Current normally flows from the arm 58 to the members 66, the buttons 68 and 78 and to the terminal contact member 7t). In the event of a current overload the bimetallic element 74 will become overheated to cause this member to spring outwardly and pull the contact button 78 out of contact with the button 63 and interrupt the circuit.

The arm 50 may be moved to any position in contact with the resistance wire 28 under the control of the handle 52 up to the limit of rotation of the handle and the shaft 24 in order to vary the amount of current supplied to the output circuit through the terminals 54 and 70. When the arm 50 is rotated to overlie a portion of the resistance element 26 by movement of the handle 52 to the right from the position indicated in FIG. 1, the arm 48 will be moved to overlie the ring segment 20. In such an event current will flow from the terminal 36 to the ring segment 18 then through the resistance wire 26 and through the arm 5%), the contact member 58, the contact member 66 and the terminal member 7 ti. Current which comes through the terminal member 34 then will flow through the ring segment 20, the arm 48, and the member 52. Thus, it can be seen that the direction of current is reversed when the arms 48 and 50 are shifted from one side of the ring segment to the other side.

The circuit includes a power indicator light 8t]; which is connected to the member 52 at one terminal and to the member 76 at its opposite terminal. The light is arranged so that it will indicate whenever power is being delivered to the output circuit through the contact terminal members 52 and 70.

in FIG. 4 there is illustrated a manner of connecting two units 32 and 34 in tandem to operate separate track sections 36 and 33 which are isolated from one another by insulation Each of the output terminals of the devices 82. and 84 are connected to track contact pistes 2 and 94 which are secured to the tracks 86 and respectively. input which in the pres. embodiment varies between twelve and sixteen volts direct current is supplied through an outwardly extending input terminal portion 96 of the element The input terminal portion 98 of the element 32 is connected through a receptacle portion of the device 84 to connect these devices for taudem operation. The element is similar to the element 36 indicated in FIG. 2 and it may be positioned within the socket id of the portion 32'. of the device 84. In order to accomplish this the input terminal screws comparable to the screws 42 and 44 are removed and the portion 36 is inserted in the socket 45 by deflecting the ends of the terminal members 3% and 36 upwardly. Since the terminal members 3 and 36 are resilient they are biased into contact with the similar terminal members of the adjacent device when it is so positioned.

Thus the invention provides a console control member particularly adapted for the operation of trains of a model railway. In the embodiments illustrated in the drawings the switch is designed for operating on a low direct current input power source. The direct power input is fed into the control through input screw terminals projecting from the right hand side of the device and the output, which is usually connected to the track, is taken from screw ter' minals projecting from the back of the device. A pilot light 36 visible through a translucent member no on the console 64 of the cover member 12 is connected to the output to indicate when the control was delivering voltage to the output circuit.

in the embodiments illustrated the control is designed to handle a maximum current of one and a half amperes and includes an overload circuit breaker bimetallic element 7 3 which interrupts the circuit when the device draws in excess of one and a half amperes. The control includes a disconnect button 62 which may be depressed to interrupt the circuit by moving the resilient member 6%! out of contact with the member The button is pro vided particularly when the device is used in association with a model railway track system including an uncoupler device which operates to uncouple trains of the units when they are positioned thereovcr and the current is discontinued. The pressing of the button 62 stops the locomotive for a moment and the tension is removed from the couplers of the train units so that they can snap open.

As illustrated in the embodiment of FIG. 4 the controls are designed so that a number of them can be plugged together to control several trains or several track sections. Each of the track sections must be insulated from the other portions. The output of each of the controls is connected to its own portion of the respective track section and controls the train operating in this section. If the train is permitted to move from one track section or block to the next its control is taken over by the next control operating in that section.

The conductive ring segments or cores id and 2% are advantageously made of highly conductive material such as copper or anodized aluminum. The core functions to conduct heat away from the resistance wire and rapidly dissipate it to the atmosphere.

While a specific embodiment of the invention has been shown and described in detail to iliustrate the appiication of the invention principles, it will be understood that the invention may be embodied otherwise without departing from such principles.

What is claimed is:

1. A direct current control device comprising a pair of input terminal members, a semi-annular conductor ring connected to each of said input terminal members, a resistance element wire connected to one end of and wound around but insulated from each of said semi-annular conductor ring segments leaving a portion of each of said segments free of such resistance wiring, a first contact arm centrally rotatably mounted between said conductor ring segments and arranged to sweep selectively over a respective one of said resistance wire windings in electrical contact therewith whereby to vary the resistance in a circuit, a first output terminal connected to said first arm, a second arm extending oppositely from said first arm and insulated from said first arm but connected thereto for rotation therewith, and arranged to sweep in electrical contact selectively with one of said conductive ring seg ments, a second terminal member connected to said second arm, and control handle means to rotate each of said first and second arms in unison.

2. A direct current control device according to claim 1, wherein said first output terminal member has an interrupted portion through which no current may pass, one of said portions having a magnetic conductive contact portion, the other of said portion having a bimetallic conductive element connected thereto and having a contact button portion which is normally biased into electrical contact with said conductive contact portion, said bimetallic arm being movable upon the application of a predetermined current overload to a position bringing said contact buttons out of electrical contact.

3. A direct current control device according to claim 2, including lamp indicator means connected across said output circuit whereby to indicate when said control device is delivering current thereto.

4. A direct current control device according to claim 1, wherein each of said input terminal members are elongated metallic strips including upstanding portions which are secured to an associated conductive ring segment.

5. A direct control device comprising a mounting plate having a central upstanding hub porton, a control shaft rotatably mounted in said hub portion, a first semi-annular conductive ring segment mounted on said base, a second semi-annular conductive ring segment mounted on said base complementary to but opposite said first conductive ring portion, first and second input terminal members connected to said first and second conductive ring segments respectively, a first resistance element wiring wound around but insulated from said first conductive ring segment, a second resistance element wiring wound around but insulated from said second conductive ring segment, a first contact sweep arm connected to said shaft for rotation therewith and extending outwardly therefrom and positioned to move in sweeping contacting engagement selectively with each of said first and second resistance elements, said conductive ring segments including portions extending outwardly from the portions having resistance wire windings, a second arm aflixed to said shaft and extending outwardly therefrom in a direction opposite from said first arm and arranged to rotate in sweeping contact with a selective one of each of said first and second conductive ring segments, a first output terminal member connected to said first arm, a second output terminal member connected to said second arm, and control means to rotate said shaft and each of said arms in unison over a selective one of said first and second resistance elements and first and second conductive ring segments whereby to vary the resistance and direction of current flow in an output circuit connected to said output terminal.

6. A direct current control device according to claim 5, including an insulation portion arranged between each end of said conductive ring segments whereby said first and second contact arm may be moved to a neutral position overlying said insulation.

7. A direct current control device according to claim 5, including a switch connected to one of said first and second output terminals.

8. A direct current control device according to claim 5, including circuit breaker means connected in one of said first and second output terminals.

9. A direct current control device according to claim 5, wherein said mounting plate includes laterally extending portions, and said input terminal members are flat strips which extend completely across said mounting plate.

10. A direct current control device according to claim 9, wherein said input terminal members on one end of said mounting plate are provided with screw means for securing input terminals thereto and the opposite ends are biased against portions of said mounting plate, and wherein said mounting plate is recessed to receive the input terminals of a similar member.

11. A direct current control device according to claim 5, including a substantially block-shaped cover member, having an inclined panel on a top face thereof, a translucent window on said panel, and light indicator means connected to said first and second output terminals and visible through said translucent window to indicate when power is being supplied to said output terminals.

12. A direct current control device according to claim 11, including a button member located on said inclined console panel and being depressible, said first output terminal including a resilient portion biased against a second portion, said button being depressible to move said resilient portion out of engagement with said second portion.

References Cited in the file of this patent UNITED STATES PATENTS 1,691,916 Brady Nov. 20, 1928 2,182,865 Franzblau Dec. 12, 1939 2,296,924 Heyer Sept. 29, 1942 2,379,530 Lederer July 3, 1945 2,479,319 Crowley Aug. 16, 1949 FOREIGN PATENTS 233,944 Great Britain Aug. 11, 1924 

